Brassiere

Abstract

A moulded brassiere having a core of a first molded foam and a laminated second foam layer. An intermediate bridge between the cups with a flexible non-stretch bridge between the cups. Outer fabric layers extend beyond the core and defining straps.

1. A molded brassiere including,
 a core assembly of at least a first layer of molded foam material and a second layer of foam material laminated with said first layer; said core assembly having a perimeter and defining two breast cup regions and an intermediate bridge region extending there between and wherein a layer of flexible material having non-stretch properties is provided intermediate of and laminated to said first and second layer of molded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region parallel to the cup to cup direction said core assembly is non-stretchable, and 
 a first and second exterior layer, each exterior layer being of at least a fabric material layer disposed outward most and each exterior layer being laminated with said core assembly on a respective side of said core assembly to encase said core assembly, said first and second exterior layers extending beyond said perimeter of said core assembly to provide at least a part of the brassiere defining chest strap(s). 
 
   
   
     2. A molded brassiere as claimed in  claim 1  wherein said first layer and said second layer of foam are laminated directly to each other except for said flexible material having non-stretch properties. 
   
   
     3. A molded brassiere as claimed in  claim 1  wherein said flexible material having non stretch properties is provided extending at said bridge region only. 
   
   
     4. A molded brassiere as claimed in  claim 1  wherein said flexible material having non stretch properties is captured intermediate of said first and second layer of molded foam material. 
   
   
     5. A molded brassiere as claimed in  claim 1  wherein said flexible material having non stretch properties is a woven fabric material. 
   
   
     6. A molded brassiere as claimed in  claim 1  wherein said flexible material having non stretch properties is a woven fabric material with bi-directional non-stretch properties and is oriented such that the non stretch orientation extends across said bridge region parallel to the cup to cup direction of said core assembly. 
   
   
     7. A molded brassiere as claimed in  claim 1  wherein said first and second layers of foam are coextensive with each other. 
   
   
     8. A molded brassiere as claimed in  claim 1  wherein said core assembly is of a shape defining only the breast cups and said bridge but not said chest strap(s). 
   
   
     9. A molded brassiere as claimed in  claim 1  wherein said chest straps extending outwardly from each side of said core assembly provided region of said molded brassiere. 
   
   
     10. A molded brassiere as claimed in  claim 1  wherein said first and second layers of foam are co extensive. 
   
   
     11. A molded brassiere as claimed in  claim 1  wherein said first and second layers of foam are laminated directly to each other except for where said flexible material having non stretch properties is provided said breast cup regions having been molded therein simultaneous to the lamination of said core assembly. 
   
   
     12. A molded brassiere as claimed in  claim 1  wherein two underwire structures are provided intermediate of said first sheet and said second layers, and each of the underwire structures is adjacent a respective one of the breast cup regions. 
   
   
     13. A molded brassiere as claimed in  claim 12  wherein said underwire structure comprises a rigid elongate member and a flexible material casing about at least part of said rigid elongate member. 
   
   
     14. A molded brassiere as claimed in  claim 13  wherein said casing is a fabric material. 
   
   
     15. A molded brassiere as claimed in  claim 13  wherein said first and second layers of foam have mutually facing surfaces, and said casing is adhered to one or each of said facing surfaces of said first and second layers of foam by an adhesive material. 
   
   
     16. A molded brassiere as claimed in  claim 13  wherein said casing is a tubular sock within which said rigid elongate member is located, said sock having closed distal ends. 
   
   
     17. A molded brassiere as claimed in  claim 1  wherein said first exterior layer is an assembly of laminated plies of a fabric material ply provided outward of said assembly and a foam ply provided inward of said fabric material ply. 
   
   
     18. A molded brassiere as claimed in  claim 17  wherein said foam layer ply of said exterior layer is laminated to said core assembly. 
   
   
     19. A molded brassiere as claimed in  claim 17  wherein said fabric material ply and said foam ply of said exterior layer are coextensive. 
   
   
     20. A molded brassiere as claimed in  claim 1  wherein said second exterior layer is an assembly of laminated plies of a fabric material ply provided outward of said assembly and a foam ply provided inward of said fabric material ply. 
   
   
     21. A molded brassiere as claimed in  claim 20  wherein said foam layer ply of said second exterior layer is laminated to said core assembly. 
   
   
     22. A molded brassiere as claimed in  claim 20  wherein said fabric material ply and said foam ply of said exterior layer are coextensive. 
   
   
     23. A method of manufacturing a molded component assembly for a brassiere comprising:
 placing a core assembly of a first layer of foam material and a second layer of foam material between which there is sandwiched a layer of flexible material having non stretch properties intermediate of two mold portions of a molding machine each portion defining a complementary shaped two cup defining molding surface, and wherein said layer of flexible fabric material is located at a region intermediate of said two cups, 
 molding said core assembly by bringing said mold portions towards each other 
 wherein the bringing together thereby subjects said core assembly to a molding force which with the combination of heat, will permanently impress two cup forms, 
 trimming said core assembly to define a molded core assembly perimeter form which includes said two cups forms and a bridge region extending there between 
 sandwiching said molded core assembly between two exterior layers of flexible material including an outer layer of a fabric material trimming said two exterior layers to define a perimeter which includes about the chest securing straps. 
 
   
   
     24. A method as claimed in  claim 23  wherein said molding of said second layer of foam material to said first layer of foam material is achieved by the placement of said second layer adjacent said first layer and applying a force pressing said second sheet and said first layer together and with the application of heat and an appropriate dwell time of pressing thereby adhering said first and second layer together. 
   
   
     25. A method as claimed in  claim 23  wherein prior to molding of said first and second layer of foam, an underwire structure intermediate of said first and second layer. 
   
   
     26. A method of making a brassiere comprising
 providing a core assembly of at least a first layer of molded foam material and a second layer of foam material laminated with said first layer of said core assembly defining two breast cup regions and an intermediate bridge region extending there between and wherein a layer of flexible material having non-stretch properties is provided intermediate of and laminated to said first and second layer of molded foam material at said bridge region, said flexible material having non-stretch properties oriented so that across the bridge region parallel to the cup to cup direction said core assembly is non-stretchable and 
 sandwiching the core assembly between a first and second exterior layer, each exterior layer comprising at least a fabric material layer disposed outward most and each laminated with said core assembly on a respective side of said core assembly to encase said core assembly, said first and second exterior layers extending beyond the perimeter of said core assembly and 
 perimeter trimming said exterior layers to provide brassiere chest strap(s). 
 
   
   
     27. A method as claimed in  claim 26  wherein each one of said two exterior layers is affixed to opposite sides of said core assembly by adhesive molding. 
   
   
     28. A method as claimed in  claim 26  wherein each one of said two exterior layers is affixed to opposite sides of said core assembly by an adhesive. 
   
   
     29. A method as claimed in  claim 28  further comprising adhering shoulder straps and a back clasp to said chest straps by ultrasonic welding.